US7422165B2 - Fuel injector with electromagnetic actuation of the plunger - Google Patents

Fuel injector with electromagnetic actuation of the plunger Download PDF

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Publication number
US7422165B2
US7422165B2 US11/253,787 US25378705A US7422165B2 US 7422165 B2 US7422165 B2 US 7422165B2 US 25378705 A US25378705 A US 25378705A US 7422165 B2 US7422165 B2 US 7422165B2
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United States
Prior art keywords
injector according
plunger
armature
electromagnet
mobile
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US11/253,787
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US20060086829A1 (en
Inventor
Fabio Cernoia
Luca Cagnolati
Massimo Mattioli
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Marelli Europe SpA
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Magneti Marelli Powertrain SpA
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Assigned to MAGNETI MARELLI POWERTRAIN S.P.A. reassignment MAGNETI MARELLI POWERTRAIN S.P.A. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CAGNOLATI, LUCA, CERNOIA, FABIO, MATTIOLI, MASSIMO
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    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
    • F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
    • F02M61/18—Injection nozzles, e.g. having valve seats; Details of valve member seated ends, not otherwise provided for
    • F02M61/188—Spherical or partly spherical shaped valve member ends
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
    • F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
    • F02M61/166—Selection of particular materials
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02—COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02M—SUPPLYING COMBUSTION ENGINES IN GENERAL WITH COMBUSTIBLE MIXTURES OR CONSTITUENTS THEREOF
    • F02M61/00—Fuel-injectors not provided for in groups F02M39/00 - F02M57/00 or F02M67/00
    • F02M61/16—Details not provided for in, or of interest apart from, the apparatus of groups F02M61/02 - F02M61/14
    • F02M61/18—Injection nozzles, e.g. having valve seats; Details of valve member seated ends, not otherwise provided for

Definitions

  • the present invention relates to a fuel injector with electromagnetic actuation of the plunger.
  • An electromagnetic fuel injector normally comprises a tubular supporting body with a central channel which performs the function of a fuel duct and ends in an injection jet regulated by an injection valve controlled by an electromagnetic actuator.
  • the injection valve is provided with a plunger, which is rigidly connected to a mobile armature of the electromagnetic actuator so as to be displaced by the action of the electromagnetic actuator between a closed position and an open position of the injection jet against the action of a spring, which tends to hold the plunger in the closed position.
  • U.S. Pat. No. 6,027,050-A1 which relates to a fuel injector provided with a plunger that, at one end, co-operates with a valve seat and at the opposite end is integral with a mobile armature of an electromagnetic actuator; the plunger is guided at the top by the armature and is guided at the bottom by sliding of the end portion of the plunger in a guide portion of the valve seat.
  • Injectors with hydraulic actuation of the plunger exhibit good dynamic performance and are capable of operating at very high fuel pressures.
  • injectors are complex and costly to produce because they require the provision of a hydraulic circuit having a piezoelectrically or electromagnetically actuated control valve.
  • a hydraulic circuit having a piezoelectrically or electromagnetically actuated control valve Injectors with hydraulic actuation of the plunger, there is always a certain degree of backflow of fuel, which is discharged at ambient pressure; such fuel backflow has two negative effects in that it wastes energy and tends to heat up the fuel.
  • US2003201346 discloses A fuel injection valve, which has an electromagnetic coil using an insulated coil wire covered with an insulating coating and having a fusion bonding layer with self-fusing properties coated over the insulating coating; therefore, it is possible to dispense with the use of a bobbin and hence possible to provide a low-cost and compact fuel injection valve that requires a reduced number of man-hours for production. Further, a flaw or a pinhole in the insulating coating is repaired by self-fusion, and thus insulation properties and waterproofness are improved; accordingly, it is possible to prevent disconnection of the coil due to electrolytic corrosion.
  • the aim of the present invention is to produce a fuel injector with electromagnetic actuation of the plunger, which injector does not exhibit the above-described disadvantages and, in particular, is straightforward and economic to produce.
  • a fuel injector is produced with electromagnetic actuation of the plunger as recited in the attached claims.
  • FIG. 1 is a diagrammatic, partially sectional, side view of a fuel injector produced according to the present invention
  • FIG. 2 shows an enlarged view of an injection valve of the injector in FIG. 1 ;
  • FIG. 3 shows an enlarged view of a pair of electromagnetic actuators of the injector in FIG. 1 ;
  • FIG. 4 shows an enlarged view of a detail of an armature of one of the electromagnetic actuators in FIG. 3 .
  • 1 denotes the overall fuel injector, which has a substantially cylindrical symmetry around a longitudinal axis 2 and is capable of being controlled so as to inject fuel from an injection jet 3 that opens directly into an explosion chamber (not shown) of a cylinder.
  • the injector 1 comprises a supporting body 4 , which has a tubular cylindrical shape of variable cross-section along the longitudinal axis 2 and has a supply channel 5 extending along the entire length of said supporting body 4 so as to supply pressurised fuel to the injection jet 3 .
  • the supporting body 4 accommodates an electromagnetic actuator 6 at the level of an upper portion thereof and an injection valve 7 (shown in FIG. 2 ) at the level of a lower portion thereof; in service, the injection valve 7 is actuated by the electromagnetic actuator 6 so as to regulate the flow of fuel through the injection jet 3 , which is produced at the level of said injection valve 7 .
  • the electromagnetic actuator 6 comprises a pair of electromagnets 8 (upper and lower respectively), each of which, when energised, is capable of displacing along the axis 2 a mobile armature 9 of ferromagnetic material from a closed position to an open position of the injection valve 7 against the action of a spring 10 that tends to hold the mobile armature 9 in the closed position of the injection valve 7 .
  • each electromagnet 8 comprises a coil 11 , which is supplied with electricity by an electronic control unit (not shown) and is accommodated outside the supporting body 4 , and a magnetic armature 12 , which is accommodated inside the supporting body 4 and has a central hole 13 to allow the fuel to flow towards the injection jet 3 .
  • an abutment member 14 is driven into a fixed position, which abutment member is of a tubular cylindrical shape (optionally open along a generating line) to allow the fuel to flow towards the injection jet 3 and is capable of holding the spring 10 in a compressed state against the mobile armature 9 of the upper electromagnet 8 .
  • Each electromagnet 8 is magnetically independent from the other electromagnet 8 and thus comprises a coil 11 separate from the coil 11 of the other electromagnet 8 , a fixed magnetic armature 12 separate from the fixed magnetic armature 12 of the other electromagnet 8 , and a mobile armature 9 separate from the mobile armature 9 of the other electromagnet 8 .
  • Each coil 11 is wound directly within a respective annular slot 15 , which is produced by removal of material from the outer surface of the supporting body 4 and has an arc-shaped cross-section to ensure maximum structural strength.
  • Each coil 11 is constituted by a conductive wire, which is enamelled and provided with a self-bonding varnish, and has a particularly small axial dimension (i.e. measured along the longitudinal axis 2 ) in order to keep dispersed magnetic flux to a minimum; in particular, each coil 11 , and thus each slot 15 , has a substantially square cross-section, i.e. having an approximately identical height and depth.
  • a protective body 16 tubular in shape, is fixed around the supporting body 4 , which protective body serves to provide sufficient mechanical protection to the coils 11 , to allow closure of the magnetic flux lines generated by the coils 11 , and to increase the mechanical strength of the supporting body 4 at the level of the structural weaknesses inevitably caused by the presence of the slots 15 .
  • the mobile armatures 9 are part of a mobile assembly, which also comprises a poppet or plunger 17 having an upper portion integral with each mobile armature 9 and a lower portion that co-operates with a valve seat 18 (shown in FIG. 2 ) of the injection valve 7 in order to regulate the flow of fuel through the injection jet 3 in known manner.
  • each mobile armature 9 is not attracted by its magnetic armature 12 and the resilient force of the spring 10 thrusts the mobile armatures 9 together with the plunger 17 downwards; in this situation, the injection valve 7 is closed.
  • each mobile armature 9 is magnetically attracted by its magnetic armature 12 against the resilient force of the spring 10 and the mobile armatures 9 together with the plunger 17 are moved upwards in order to bring about opening of the injection valve 7 .
  • the mobile armature 9 of the upper electromagnet 8 has an effective stroke that is shorter than the effective stroke of the mobile armature 9 of the lower electromagnet 8 . In this manner, when the electromagnets 8 are energised, it is always only the mobile armature 9 of the upper electromagnet 8 that strikes its magnetic armature 12 irrespective of any inevitable structural tolerances.
  • the lower surface of the armature 12 or the upper surface of the mobile armature 9 is covered with a layer of a hard and non-ferromagnetic metallic material, preferably chromium; in this manner, the thickness of the layer of chromium determines the reduction in the effective stroke of the mobile armature 9 of the upper electromagnet 8 .
  • Further functions of the chromium layer are to increase the impact resistance of the zone and, especially, to avoid magnetic adhesion phenomena due to direct contact between the ferromagnetic material of the mobile armature 9 and the ferromagnetic material of the armature 12 .
  • the chromium layer defines a magnetic gap, which prevents the magnetic attraction forces due to the residual magnetism between the mobile armature 9 and the armature 12 from becoming too high, i.e. exceeding the resilient force generated by the spring 10 .
  • the valve seat 18 is defined by a sealing member 19 , which seals the bottom of the supply channel 5 of the supporting body 4 , and is passed through by the injection jet 3 .
  • the sealing member 19 is screwed inside the supporting body 4 in order to ensure the mechanical tightness of the joint and is subsequently welded to said supporting body 4 in order to ensure the hydraulic tightness of the joint.
  • the plunger 17 ends in a plugging head 20 , substantially spherical in shape, which is capable of resting in sealing manner against the valve seat 18 .
  • the sealing member 19 has an annular guide member 21 , on which the plugging head 20 rests so that it can slide; the function of the guide member 21 is to define a lower guide for the movement of the plunger 17 along the longitudinal axis 2 .
  • the plugging head 20 has four flattened portions 22 (only three of which are visible in FIG. 2 ) at the level of the guide member 21 so as to create four passages for the fuel towards the injection jet 3 .
  • the injection jet 3 is defined by a plurality of injection through-holes 23 (only two of which are shown in FIG. 2 ), which are produced starting from a hemispherical injection chamber 24 arranged immediately downstream from the valve seat 18 .
  • each mobile armature 9 comprises an annular member 25 and a discoid member 26 , which closes off the bottom of the annular member 25 and has a central through-hole 27 capable of receiving an upper portion of the plunger 17 and a plurality of peripheral supply through-holes 28 (only two of which are shown in FIG. 4 ) capable of allowing the fuel to flow towards the injection jet 3 .
  • the plunger 17 is preferably made integral with the discoid member 26 of each mobile armature 9 by means of an annular weld. A central portion of the discoid member 26 of the mobile armature 9 of the upper electromagnet 8 abuts against a lower end of the spring 10 .
  • each mobile armature 9 has an external diameter substantially identical to the internal diameter of the corresponding portion of the supply channel 5 of the supporting body 4 ; in this manner, each mobile armature 9 can slide relative to the supporting body 4 along the longitudinal axis 2 , but cannot make any movement transverse to the longitudinal axis 2 , relative to the supporting body 4 . Since the plunger 17 is rigidly connected to each mobile armature 9 , it is clear that each mobile armature 9 also acts as an upper guide for the plunger 17 ; as a result, the plunger 17 is guided at the top by the mobile armatures 9 and at the bottom by the guide member 21 .
  • An antirebound device 29 of the hydraulic type is attached to the lower face of the discoid member 26 of each mobile armature 9 , which antirebound device is capable of damping the rebound of the plugging head 20 of the plunger 17 against the valve seat 18 when the plunger 17 moves from the open position to the closed position of the injection valve 7 .
  • Each antirebound device 29 comprises respective valve members 30 , each of which is coupled with a respective peripheral supply hole 28 of the mobile armature 9 and has a different permeability to the passage of the fuel depending upon the direction of passage of said fuel through the supply hole 28 .
  • each valve element 30 comprises a resilient sheet 31 , which is in part fixed to a lower surface 32 of the mobile armature 9 on only one side of the respective supply hole 28 and comprises a hole 33 of smaller dimensions aligned with said supply hole 28 ; when the fuel flows downwards, i.e. towards the injection jet 3 , the sheet 31 deforms under the thrust of the fuel, allowing the fuel to flow substantially freely through the supply hole 28 , while, when the fuel flows upwards, the sheet 31 is pressed against the lower surface 32 of the mobile armature 9 by the thrust of the fuel, closing the supply hole 28 and allowing the fuel to flow only through its smaller dimension hole 33 .
  • each antirebound device 29 constitutes an asymmetric system for damping the kinetic energy of the corresponding mobile armature 9 .
  • the plunger 17 has a rod 34 with cylindrical symmetry, to which is connected the substantially spherical plugging head 20 by means of an annular weld.
  • the upper surface of the mobile armature 9 may not be perfectly plane and perfectly parallel to the lower surface of the magnetic armature 12 and the plunger 17 may not be perfectly perpendicular relative to the mobile armature 9 ; consequently, when the mobile armature 9 comes to a standstill against the magnetic armature 12 , direct transverse stresses perpendicular to the longitudinal axis 2 may be generated on the mobile armature 9 . A proportion of such transverse stresses is also transmitted to the plunger 17 and is dissipated at the level of the coupling between the plugging head 20 of the plunger 17 and the guide member 21 .
  • the rod 34 of the plunger 17 in such a manner as to impart to said rod 34 relatively high flexibility (or in other words relatively low flexural rigidity), which flexibility is certainly greater than that normally present in known, currently commercially available injectors; it has in fact been observed that increasing the flexibility of the rod 34 reduces the transmission of transverse stresses from the mobile armature 9 to the plugging head 20 .
  • the rod 34 of the plunger 17 is sufficiently flexible, the transmission of transverse stresses from the mobile armature 9 to the plugging head 20 is reduced and it is then no longer necessary to precision-machine the components with the aim of achieving very tight structural tolerances.
  • the rod 34 of the plunger 17 must not be too flexible, because if it were too flexible it would not be capable of ensuring rapid and precise control of the injection valve 7 .
  • a flexibility parameter P f which is a reliable indicator of the flexibility of the rod 34 and has the dimensions of a pressure (N/mm 2 ). It is important to note that, since the flexibility parameter P f has the dimensions of a pressure (N/mm 2 ), said flexibility parameter Pf can be traced back to the phenomenon of contact/impact pressure wear between the plugging head 20 and the guide member 21 .
  • K eq ( E*D s 4 )/(6.8 *L s 3 )
  • the flexibility parameter P f In order to achieve the desired effect of limiting the transmission of the transverse stresses from the mobile armature 9 to the plugging head 20 without however prejudicing the performance of the injection valve 7 , the flexibility parameter P f must be between 0.3 and 4 N/mm 2 .
  • the flexibility parameter P f is preferably between 0.4 and 0.8 N/mm 2 and is substantially equal to approx 0.6 N/mm 2 .
  • the cross-section of the rod 34 can be varied, a material of greater or lesser elasticity can be used to produce the rod 34 , the cross-sectional shape of the rod 34 can be varied.
  • the above-described injector 1 is simple and economic to manufacture because it is produced in its entirety by combining components which are of cylindrical symmetry and can thus readily be obtained by turning and drilling operations. Moreover, the above-described injector 1 makes it possible to operate with very high fuel pressures (by way of information, up to 160 MPa) without exhibiting significant load losses.

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Fuel-Injection Apparatus (AREA)
US11/253,787 2004-10-20 2005-10-20 Fuel injector with electromagnetic actuation of the plunger Active 2026-09-02 US7422165B2 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT000649A ITBO20040649A1 (it) 2004-10-20 2004-10-20 Iniettore di carburante con attuazione elettromagnetica dello spillo
ITBO2004A000649 2004-10-20

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US20060086829A1 US20060086829A1 (en) 2006-04-27
US7422165B2 true US7422165B2 (en) 2008-09-09

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US11/253,787 Active 2026-09-02 US7422165B2 (en) 2004-10-20 2005-10-20 Fuel injector with electromagnetic actuation of the plunger

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US (1) US7422165B2 (it)
EP (1) EP1650428B1 (it)
CN (1) CN1776214B (it)
AT (1) ATE519939T1 (it)
BR (1) BRPI0504514B1 (it)
IT (1) ITBO20040649A1 (it)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090293846A1 (en) * 2005-04-28 2009-12-03 Wärtsilä Finland Oy A control system of a fuel injection apparatus of an internal combustion engine
US20110127357A1 (en) * 2009-12-02 2011-06-02 Robert Bosch Gmbh Electromagnetic valve for controlling an injector or for regulating pressure of a high-pressure fuel accumulator
CN102162419A (zh) * 2011-04-01 2011-08-24 宁波舜田良源油嘴油泵有限公司 一种柴油机双缸分列式喷油泵
US8840048B2 (en) 2009-03-25 2014-09-23 Continental Automotive Gmbh Injection valve
US11371472B2 (en) * 2018-03-15 2022-06-28 Denso Corporation Corrosion resistant device
KR20230070719A (ko) 2021-11-15 2023-05-23 주식회사 현대케피코 스프링리스 바운싱 저감 타입 인젝터

Families Citing this family (7)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
PT1911963E (pt) * 2006-10-10 2009-03-10 Magneti Marelli Spa Sistema de fornecimento de combustível por injecção electrónica
US20090057446A1 (en) * 2007-08-29 2009-03-05 Visteon Global Technologies, Inc. Low pressure fuel injector nozzle
US7669789B2 (en) 2007-08-29 2010-03-02 Visteon Global Technologies, Inc. Low pressure fuel injector nozzle
DE102012202538A1 (de) * 2012-02-20 2013-08-22 Robert Bosch Gmbh Kraftstoffinjektor
ITBO20130169A1 (it) * 2013-04-17 2014-10-18 Magneti Marelli Spa Iniettore elettromagnetico di carburante con dispositivo frenante
EP2975256B1 (en) * 2014-07-14 2016-07-27 Magneti Marelli S.p.A. Electromagnetic fuel injector with hydraulic braking device
CN113262944B (zh) * 2021-05-31 2022-08-02 商丘师范学院 一种磁激励导磁高粘胶液微量分配装置及方法

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US5100102A (en) * 1990-10-15 1992-03-31 Ford Motor Company Compact electronic fuel injector
US5769391A (en) 1995-02-06 1998-06-23 Robert Bosch Gmbh Electromagnetically actuated valve
US5881957A (en) * 1996-03-26 1999-03-16 Denso Corporation Nozzle structure of fuel injector for internal combustion engine
US6318646B1 (en) * 1999-03-26 2001-11-20 MAGNETI MARELLI S.p.A. Fuel injector
US6373363B1 (en) 2000-03-28 2002-04-16 Delphi Technologies, Inc. Dual coil solenoid for a gas direct injection fuel injector
US20030201346A1 (en) 2002-04-24 2003-10-30 Yukinori Kato Fuel injection valve
EP1369571A1 (en) 2002-06-07 2003-12-10 Magneti Marelli Powertrain S.p.A. Method for controlling a fuel injector according to a control law which is differentiated as a function of injection time
US6796511B2 (en) * 2000-02-04 2004-09-28 Robert Bosch Gmbh Fuel injection valve and a method for operating the same
US7032846B1 (en) * 1999-07-08 2006-04-25 Robert Bosch Gmbh Fuel injection valve

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GB9725802D0 (en) 1997-12-06 1998-02-04 Lucas Ind Plc Fuel injection
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JP3884310B2 (ja) * 2002-03-22 2007-02-21 愛三工業株式会社 電磁式燃料噴射弁

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Publication number Priority date Publication date Assignee Title
US4295111A (en) * 1979-11-29 1981-10-13 Nasa Low temperature latching solenoid
US5100102A (en) * 1990-10-15 1992-03-31 Ford Motor Company Compact electronic fuel injector
US5769391A (en) 1995-02-06 1998-06-23 Robert Bosch Gmbh Electromagnetically actuated valve
US5881957A (en) * 1996-03-26 1999-03-16 Denso Corporation Nozzle structure of fuel injector for internal combustion engine
US6318646B1 (en) * 1999-03-26 2001-11-20 MAGNETI MARELLI S.p.A. Fuel injector
US7032846B1 (en) * 1999-07-08 2006-04-25 Robert Bosch Gmbh Fuel injection valve
US6796511B2 (en) * 2000-02-04 2004-09-28 Robert Bosch Gmbh Fuel injection valve and a method for operating the same
US6373363B1 (en) 2000-03-28 2002-04-16 Delphi Technologies, Inc. Dual coil solenoid for a gas direct injection fuel injector
US20030201346A1 (en) 2002-04-24 2003-10-30 Yukinori Kato Fuel injection valve
EP1369571A1 (en) 2002-06-07 2003-12-10 Magneti Marelli Powertrain S.p.A. Method for controlling a fuel injector according to a control law which is differentiated as a function of injection time

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Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US20090293846A1 (en) * 2005-04-28 2009-12-03 Wärtsilä Finland Oy A control system of a fuel injection apparatus of an internal combustion engine
US7665443B2 (en) * 2005-04-28 2010-02-23 Wärtsilä Finland Oy Control system of a fuel injection apparatus of an internal combustion engine
US8840048B2 (en) 2009-03-25 2014-09-23 Continental Automotive Gmbh Injection valve
US20110127357A1 (en) * 2009-12-02 2011-06-02 Robert Bosch Gmbh Electromagnetic valve for controlling an injector or for regulating pressure of a high-pressure fuel accumulator
US9714634B2 (en) * 2009-12-02 2017-07-25 Robert Bosch Gmbh Electromagnetic valve for controlling an injector or for regulating pressure of a high-pressure fuel accumulator
CN102162419A (zh) * 2011-04-01 2011-08-24 宁波舜田良源油嘴油泵有限公司 一种柴油机双缸分列式喷油泵
CN102162419B (zh) * 2011-04-01 2012-10-17 宁波舜田良源油嘴油泵有限公司 一种柴油机双缸分列式喷油泵
US11371472B2 (en) * 2018-03-15 2022-06-28 Denso Corporation Corrosion resistant device
KR20230070719A (ko) 2021-11-15 2023-05-23 주식회사 현대케피코 스프링리스 바운싱 저감 타입 인젝터

Also Published As

Publication number Publication date
EP1650428A3 (en) 2006-10-04
US20060086829A1 (en) 2006-04-27
ATE519939T1 (de) 2011-08-15
BRPI0504514B1 (pt) 2018-04-17
BRPI0504514A (pt) 2006-06-27
EP1650428A2 (en) 2006-04-26
CN1776214B (zh) 2010-08-25
ITBO20040649A1 (it) 2005-01-20
CN1776214A (zh) 2006-05-24
EP1650428B1 (en) 2011-08-10

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